Less toxic mattress

ABSTRACT

A mattress and method of constructing the mattress having a reduced toxicity has a cover or an outermost layer including food grade polyethylene. Also, the outer layer of the mattress can also be constructed from a material selected from the same group of materials. Food grade polyethylene films are non-toxic materials which reduce adverse human health effects due to the exposure to potentially harmful chemicals used in the mattress construction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/391,536, filed Dec. 27, 2016, which is acontinuation-in-part of U.S. patent application Ser. No. 15/042,167,filed Feb. 12, 2016, which is a continuation of U.S. patent applicationSer. No. 12/044,456, filed Mar. 7, 2008, now U.S. Pat. No. 9,259,096,issued Feb. 16, 2016, which claims the benefit under 35 U.S.C. § 119(e)to U.S. Provisional Patent Application Ser. No. 60/939,418, filed May22, 2007, and 60/893,939, filed Mar. 9, 2007; the disclosures of whichare incorporated herein by reference in their entirety.

FIELD OF INVENTION

The present invention relates to mattress materials that significantlyreduce any potential human harm due to exposure to the mattressmaterials. More specifically, the present invention relates to a methodfor processing and constructing mattress materials to reduce thetoxicity of a mattress in order to reduce the risk of adverse humanallergic reaction or exposure to potentially harmful chemicals due tothe materials or material impurities used in the mattress construction.

BACKGROUND

There are various mattress constructions that use materials that, bythemselves or due to some material or chemical impurities, can cause oraggravate human allergenic reactions and/or can result in otherpotentially harmful exposures. For example, materials that incorporatepolyurethanes, polyvinyl chlorides, polystyrenes, or polycarbonates cancontain hazardous substances that are potentially harmful to humanhealth, safety, and the environment.

A mattress cover is typically the outermost layer or combination oflayers in the assembled mattress. The mattress cover, or outermostlayer, functions to isolate the mattress from the human body. That is,the outermost layer is primarily used to provide a barrier between themattress and the person, limiting deterioration of the mattress andabove all preventing the passage of potentially irritating or harmfulsubstances, bacteria or parasites from the mattress to the person. Themattress may contain materials or chemicals, which can pass through thesurface of the mattress and may irritate the skin, lungs or othersensitive areas of a human. Furthermore, as time passes, the surfacelayers of the mattress are subject to deterioration and/or contaminationwith bacteria and parasites. Being that the outermost layer can be inclose proximity to, or in contact with a user's skin, eyes, mouth, andnostrils, it is preferable not to allow any water soluble or volatileorganic solvent, chemical contaminant or material impurity in theoutermost layer or in the mattress itself. If any of these materialswere to be adsorbed by the skin, mouth, and the eyes, and inhaled intothe mucous membranes and the lungs, they may cause a negative effect onthe user's health.

For example, the deteriorated and/or contaminated surface of theoutermost layer can cause skin irritation and/or other types of allergicor adverse reactions. More specifically, there are risks that themovement of air over and through the outermost layer can transportchemical impurities or chemical contaminants arising from the mattressmaterials to the sensitive skin or lungs of infants, asthmatics orhyper-allergenic humans.

The typical exposure to a mattress used in bedding and furniture canrange from about 6 hours per day for adults to as high as 18 hours ormore per day for infants. Due to the typically high amount of exposureto mattress materials, there is a need for a non-toxic materialconstruction of the outermost layer as well as the mattress itself.

In some cases, fabrics have been treated with an antibacterial thatminimizes the growth of bacteria and mold. However, these chemicals canleach out of the substrate and become less effective. In addition, someantimicrobials, such as Triclosan(5-chloro-2-(2,4-dichlorophenoxy)phenol), commonly used in a variety ofconsumer goods including fabrics, have been linked to hormone regulationin animals (U.S. FDA/UCM205999). There is therefore a need for anoutermost layer that is non-toxic and can provide an effective barrierthat is biocompatible, comfortable for the user and is still waterproof.

SUMMARY

The present invention is directed to a non-toxic mattress cover, oroutermost layer. The outermost layer can be constructed from food gradeplastics that do not contain materials that may be harmful to humans.

The U.S. Food & Drug Administration (FDA) sets standards for plasticresins used in food packaging to be of greater purity than plastics usedfor non-food packaging. This is commonly referred to as food gradeplastic. Food grade plastics do not contain materials that may beharmful to humans.

It has been found that outermost layers made from food grade Low DensityPolyethylene (LDPE), which includes Linear Low Density Polyethylene(LLDPE) or a blend of LDPE and LLDPE and its copolymers or homopolymersthat meet FDA standards, offer less toxicity and can eliminate or reduceadverse human health effects due to the mattress construction materialsor their impurities, and especially when used as the outermost layermaterial. When food grade LLDPE or a blend of LDPE and LLDPE are usedfor food containers, they are known to be non-toxic. The outermost layermay also include Polylactic Acid (PLA) and the PLA can be blended withfood grade LDPE, food grade LLDPE, or combinations thereof.

It is also within the terms of the present invention to use materials,such as sourced from potatoes, corn, sugar cane or biopolymers, such asPLA, naturally occurring zein, the principle protein of corn, orpoly-3-hydroxybutyrate based films and laminates to maximize therenewable and recyclable materials content. Alternatively, it could alsobe sourced from a petroleum based material.

It is also within the terms of the present invention to construct amattress using organically grown cotton, wool or other fibers batting inorder to eliminate any possible agricultural pesticide or chemicalfertilizer contamination. This organic cotton batting can be treatedwith ozone gas or other sanitizing processes to clean, oxidize, andremove other possible hazardous processing substances commonly used intextile manufacturing.

According to an example embodiment of the present invention, there isdisclosed a non-toxic mattress that has a reduced level of toxicity.Without limitation, the toxicity of the mattress in whole or anyindividual mattress layers or combination thereof can be reduced tolevels that are relatively non-toxic or non-toxic, for example, meetingthe UL GREENGUARD Gold Standard, the Global Organic Textile Standard(GOTS), or Made Safe Standard. Other non-toxic materials are alsopossible that do not meet one of these standards. The non-toxic mattressincludes an outer layer of the mattress which can include food gradeLDPE, food grade LLDPE, PLA, or mixtures thereof. A next lower layer ofthe mattress can be encompassed by the outer layer. An inner cushioninglayer of the mattress can be encompassed by the outer layer and the nextlower layer of the mattress. An innermost component of the mattress canbe embedded within the inner cushioning layer. The inner cushioninglayer and innermost components can include the inner material asdisclosed herein. The layers can also be constructed in a differentorder. For example, the next lower layer could include the non-toxicmaterial, while the outermost layer is something else.

Further according to another example embodiment of the presentinvention, the non-toxic mattress includes a non-toxic mattress cover oroutermost layer for covering the outer layer of the mattress. Themattress cover or outermost layer can be constructed from materialsincluding food grade polyethylene including polyethylene derived frompetrochemicals or natural feedstocks (i.e., sugar cane), Polyester, PLApolymers or films or a combination of both or other such fabrics.

Still further according to another example embodiment of the presentinvention, the mattress cover or outermost layer can be constructed ofor further contain a PLA film including homopolymers and copolymers oflactic acid containing at least 50 mole % lactic acid units and mixturesthereof having a number average molecular weight of 3,000-200,000 g/mol.

Moreover, according to the present invention, the mattress cover oroutermost layer is constructed from a film made of food gradepolyethylene (LDPE and/or LLDPE) and/or PLA which has been FDAclassified as Generally Recognized as Safe (GRAS) or a combination ofpolyethylene and PLA.

According to another example embodiment of the present invention, thepolyethylene included in the utermost layer can be a film that has adensity of 0.85 to 1.00 grams per cubic centimeter (g/cc); a maximumextractable fraction (expressed as percent by weight of the polymer) inn-hexane at specified temperatures is 5.5% at 50° C.); and a maximumextractable fraction (expressed as percent by weight of the polymer) inxylenes at specified temperatures is 11.3% at 25° C.

According to another example embodiment of the present invention, thenon-toxic mattress includes an outer layer. The outer layer can beconstructed from materials including polyethylene, PLA polymers or filmsand combinations thereof.

According to another example embodiment of the present invention, theouter layer of the mattress can be constructed of, or further containPLA including homopolymers and copolymers of lactic acid containing atleast 50 mole % lactic acid units and mixtures thereof having a numberaverage molecular weight of 3,000-200,000 g/mol.

In addition, the outer layer of the mattress can be constructed of apolymer of PLA which has been FDA classified as Generally Recognized asSafe (GRAS) and/or food grade LDPE and/or LLDPE that meets FDAguidelines.

According to another example embodiment of the present invention, thepolyethylene included in the outer layer of the mattress has a densityof 0.85 to 1.00 g/cc; a maximum extractable fraction (expressed aspercent by weight of the polymer) in n-hexane at specified temperaturesis 5.5% at 50° C.; and a maximum extractable fraction (expressed aspercent by weight of the polymer) in xylenes at specified temperaturesis 11.3% at 25° C.

According to another example embodiment of the present invention, theouter layer of the mattress can be heat fused to a substrate within themattress so as to provide improved tensile strength and tear resistanceto the outer layer of the mattress. The fabric substrate can beconstructed of materials including cotton, organic cotton, polyester,polypropylene etc. or combinations thereof.

According to another example embodiment of the present invention, thenext lower layer of the mattress can include a fabric flame barrier,which acts like a flame retardant instead of toxic halogenated flameretardants that are commonly used.

According to another example embodiment of the present invention, theinner cushioning layer of the mattress, which provides vibrationdampening, insulation and cushioning, is constructed of a materialselected from the group consisting of organic cotton batting, food gradepolyethylene, (LDPE and/or LLDPE), PLA polymer or foam, latex or wool.

According to another example embodiment of the present invention, theinnermost component of the mattress is constructed of a support materialthat gives the non-toxic mattress the necessary strength, maintains thedesired shape of the mattress, provides the majority of the cushioningrequirements and provides the required weight support.

According to another example embodiment of the present invention, themattress cover or outermost layer and the outer layer of the mattresscan be constructed of a material made from a material that may besourced from potatoes, corn, sugar cane, a biopolymer, such as PLA,naturally occurring zein, or poly-3-hydroxybutyrate based films andlaminates to maximize the renewable and recyclable materials content orpolyurethane or polyethylene foam.

According to another example embodiment of the present invention, themattress cover or outermost layer made from food grade polyethylene,(LDPE and LLDPE) can be in close proximity to or in contact with auser's skin. The mattress may also be appropriately sized to fit abassinet, crib, cradle, or bed.

According to another example embodiment of the present invention, thereis also disclosed a method for constructing a mattress with reducedtoxicity. The method can include the steps of (a) forming a food gradeLow Density Polyethylene (LDPE) and/or Linear Low Density Polyethylene(LLDPE) cover or outermost layer; (b) forming an outer layer contactingthe food grade LDPE and LLDPE; and (c) forming an inner materialcontacting the outer material. The inner material can include an innercushioning layer that contains innermost components that are part of orembedded within the inner cushioning layer.

According to another example embodiment of the present invention, theouter layer of the mattress is covered with a mattress cover oroutermost layer constructed from a material including a polyethylenefilm and/or a PLA film or a combination of both.

According to another example embodiment of the present invention, themattress cover or outermost layer is constructed of a film of a foodgrade polymer of PLA, which has been FDA classified as GenerallyRecognized as Safe (GRAS), and/or a food grade polyethylene such as LDPEor LLDPE.

According to another example embodiment of the present invention, theouter layer of the mattress is heat fused to a substrate within themattress so as to provide improved tensile strength and tear resistanceto the outer layer of the mattress.

According to another example embodiment of the present invention, thenext lower layer of the mattress can be constructed of a fabric flamebarrier, which acts as a flame retardant rather than the toxichalogenated flame retardants commonly used.

According to another example embodiment of the present invention, theoutermost layer and the outer layer of the mattress is constructed of amaterial made from a material. The material may be sourced frompotatoes, sugar cane, corn, a biopolymer, such as PLA, naturallyoccurring zein, or poly-3-hydroxybutyrate based films and laminates tomaximize the renewable and recyclable materials content.

According to another example embodiment of the present invention, themattress cover or outermost layer including food grade LDPE and LLDPEcan be in close proximity to, or in contact with a user's skin. Themattress may also be appropriately sized to fit a bassinet, crib,cradle, or bed.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention may become apparent to those skilledin the art with the benefit of the following detailed description andupon reference to the accompanying drawings.

FIG. 1 is an illustration of a mattress in one example embodiment of thepresent invention.

FIG. 2A is an illustration of a mattress in one example embodiment ofthe present invention.

FIG. 2B is an illustration of a mattress in one example embodiment ofthe present invention.

FIG. 2C is an illustration of a mattress in one example embodiment ofthe present invention.

FIG. 2D is an illustration of a mattress in one example embodiment ofthe present invention.

FIG. 3A is an embodiment of a bassinet pad according to one embodimentof the disclosure.

FIG. 3B is an embodiment of a mattress pad according to one embodimentof the disclosure.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings. The drawings may not be to scale.

DETAILED DESCRIPTION OF ILLUSTRATIVE EXAMPLES

In the description that follows, numerous details are set forth in orderto provide a thorough understanding of the present invention. It will beappreciated by those skilled in the art that variations of thesespecific details are possible while still achieving the results of thepresent invention. Well-known processing steps and materials aregenerally not described in detail in order to avoid unnecessarilyobfuscating the description of the present invention.

Throughout the descriptions set forth in this disclosure, lowercasenumbers or letters may be used, instead of subscripts. For example Vgcould be written Vg. Generally, lowercase is preferred to maintainuniform font size. Regarding the use of subscripts throughout the textof this document, sometimes a character (letter or numeral) is writtenas a subscript—smaller, and lower than the character (typically aletter) preceding it, such as “Vs” (source voltage) or “H2O” (water).For consistency of font size, such acronyms may be written in regularfont, without subscripting, using uppercase and lowercase—for example“Vs” and “H2O”. Materials (e.g., silicon dioxide) may be referred to bytheir formal and/or common names, as well as by their chemical formula.Regarding chemical formulas, numbers may be presented in normal fontrather than as subscripts. For example, silicon dioxide may be referredto simply as “oxide”, chemical formula SiO2. For example, siliconnitride (stoichiometrically Si3N4, often abbreviated as “SiN”) may bereferred to simply as “nitride”.

The term “non-toxic” when used in this specification to describe amaterial or component means that the material meets at least one of thefollowing toxicity standards: UL GREENGUARD Gold Standard, the GlobalOrganic Textile Standard (GOTS), or the Made Safe Standard. Non-toxicmaterial may be fibers, textiles, fabrics, and layers of a mattress.Non-toxic material may include, without limitation, Low DensityPolyethylene (LDPE), Linear Low Density Polyethylene (LLDPE),ultra-high-molecular-weight polyethylene (UHMWPE),ultra-low-molecular-weight polyethylene (ULMWPE or PE-WAX),high-molecular-weight polyethylene (HMWPE), high-density polyethylene(HDPE), high-density cross-linked polyethylene (HDXLPE), cross-linkedpolyethylene (PEX or XLPE), medium-density polyethylene (MDPE),very-low-density polyethylene (VLDPE), chlorinated polyethylene (CPE),Polylactic acid (PLA), polylactide, poly-L-lactide (PLLA),poly-DL-lactide (PDLLA), or combinations thereof. Non-toxic material mayalso include, without limitation, those categorized within ResinIdentification Codes 1 (polyethylene terephthelate), 2 (high-densitypolyethylene), 4 (low-density polyethylene), 5 (polypropylene), 6(polystyrene), or 7 (other plastics, such as polycarbonate, PLA, andacrylic). In preferred aspects, when these polymers are included in anylayer of the mattress they can also be food grade by FDA guidelines,such as those polymers provided in 21 C.F.R. 174-190. The abovementioned non-toxic materials may also be waterproofing materials.

In the description that follows, the dimensions should not beinterpreted as limiting. They are included to provide a sense ofproportion. Generally speaking, it is the relationship between variouselements, where they are located, their contrasting compositions, andsometimes their relative sizes that is of significance.

According to the present invention, there is described materials and aprocess for reducing the toxicity of mattress covers or outermost layersand mattress construction so as to reduce the risk of undesirable humanhealth effects that may be caused by harmful exposures to mattressconstruction materials or their impurities. In a non-limiting aspect,the cover and outermost layer of the mattress can be the same layers ofthe mattress described. In one instance, a mattress cover can beremovable from the mattress and in another instance the outermost layercan be integral with the mattress.

A mattress cover or outermost layer, according to the present invention,is constructed of a food grade polymer, Polylactic Acid (PLA) which hasbeen FDA classified as Generally Recognized as Safe (GRAS), and/or afood grade Low Density Polyethylene (LDPE) or Linear Low DensityPolyethylene (LLDPE), or a combination of a polyethyelene with PLA thatmeets either of these FDA guidelines: 177.1520, 21 CFR Ch. I (4-1-03Edition) Olefin Polymers:

Section 2.1, Page 281: Polyethylene for use in articles that contactfood except for articles used for packing or holding food duringcooking. The polyethylene film meets this FDA specification:1. Density is 0.85 to 1.00 grams per cubic centimeter (g/cc).2. Maximum extractable fraction (expressed as percent by weight of thepolymer) in N-Hexane at specified temperatures is 5.5% at 50 DegreesCentigrade (Deg C.).3. Maximum extractable fraction (expressed as percent by weight of thepolymer) in xylene at specified temperatures is 11.3% at 25 Deg C.

OR

Section 2.3, Page 281: Polyethylene for use only as component offood-contact coatings at levels up to and including 50 percent by weightof any mixture employed as a food-contact coating. The Polyethylene filmmeets this FDA specification:1. Density is 0.85 to 1.00 g/cc.2. Maximum extractable fraction (expressed as percent by weight of thepolymer) in N-Hexane at specified temperatures is 53% at 50° C.3. Maximum extractable fraction (expressed as percent by weight of thepolymer) in xylenes at specified temperatures is 75% at 25° C.

Polyethylene is a polymer consisting of long chains of the monomerethylene (IUPAC name ethene). Polyethylene is created throughpolymerization of ethylene in the presence of catalysts such as ZieglerNatta catalysts, i.e. titanium (III) chloride.

LDPE is defined by a density range of 0.850-1.000 g/cc. LDPE has a highdegree of short and long chain branching, which means that the chains donot pack into the crystal structure as well. It has therefore lessstrong intermolecular forces, since the instantaneous-dipoleinduced-dipole attraction is lower. This results in a lower tensilestrength and increased ductility. LDPE is created by free radicalpolymerization. The high degree of branches with long chains givesmolten LDPE unique and desirable flow properties. LDPE has been used forboth rigid containers and plastic film applications such as plastic bagsand film wrap.

LLDPE is defined by a narrow density range of 0.915-0.925 g/cc. LLDPE isa linear polymer with significant numbers of short branches, made bycopolymerization of ethylene with longer-chain olefins. LLDPE differsstructurally from LDPE because of the absence of long chain branching.The linearity of LLDPE results from the different manufacturingprocesses of LLDPE and LDPE. In general, LLDPE is produced at lowertemperatures and pressures by copolymerization of ethylene with higheralpha-olefins such as butene, hexene, or octene. The weight or molarpercentage of higher alpha-olefins copolymerized ethylene in the LLDPEof the present invention can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, 18, 19, 20%, or any range there between. Thecopolymerization process produces a LLDPE polymer that has a narrowermolecular weight distribution than LDPE and in combination with thelinear structure, significantly different rheological properties. LLDPEis less shear sensitive because of its narrower molecular weightdistribution and shorter chain branching. LLDPE has higher tensilestrength than LDPE, and it exhibits higher impact and punctureresistance than LDPE. The less-toxic mattress of the present inventionmay include LLDPE to improve durability, barrier effect, orwaterproofing. In one instance, the LDPE and/or LLPDE helps provide abarrier against water base stains. Lower thickness (gauge) films can beblown when compared with LDPE. LLDPE is used in packaging, particularlyfilm for bags and sheets. LLDPE is used predominantly in filmapplications due to its toughness, flexibility, and relativetransparency.

Without being limited to theory, the mattress of the present inventioncan also contain any of ultra-high-molecular-weight polyethylene(UHMWPE), ultra-low-molecular-weight polyethylene (ULMWPE or PE-WAX),high-molecular-weight polyethylene (HMWPE), high-density polyethylene(HDPE), high-density cross-linked polyethylene (HDXLPE), cross-linkedpolyethylene (PEX or XLPE), medium-density polyethylene (MDPE),very-low-density polyethylene (VLDPE), chlorinated polyethylene (CPE),or combinations thereof. The above mentioned polyethyene-based polymersare generally classified by their densities which give them uniquestructural and physical/chemical properties. As such, any plastic withphysical and chemical properties similar to those described herewithin(e.g., low density, less toxicity, etc.) may be incorporated into anyone of the disclosed embodiments. Exemplary plastics may include,without limitation, those categorized within Resin Identification Codes1 (polyethylene terephthelate), 2 (high-density polyethylene), 4(low-density polyethylene), 5 (polypropylene), 6 (polystyrene), or 7(other plastics, such as polycarbonate, PLA, and acrylic). In preferredaspects, when these polymers are included in any layer of the mattressthey can also be food grade by FDA guidelines, such as those polymersprovided in 21 C.F.R. 174-190.

In some aspects, food grade LDPE and LLDPE polymers can be providedtogether in compositions, materials, layers, or films of the currentinvention. In one aspect, food grade LDPE and LLDPE are provided and areseparated as layered films. The films can be adhered using knownequipment and methods (e.g. lamination and the like). In a particularaspect, the food grade LDPE and LLDPE are mixed together in a polymerblend. The weight or molar ratio of LDPE to LLDPE in the polymer blendcan be any value from 99:1 to 1:99 or any range or value there between.

Polylactic acid (PLA) or polylactide is a biodegradable, thermoplastic,aliphatic polyester derived from renewable resources such as corn.Polylactide, (O—CH(—CH3)-C(═O)}n, is easily produced in a high molecularweight form through ring-opening polymerization using most commonly astannous octoate catalyst, but for laboratory demonstrations, tin (II)chloride is often employed.

According to the present invention, suitable polymers for use inconstructing the mattress covers or outermost layers and possibly partof the mattress itself are PLA homopolymers and copolymers of lacticacid containing at least 50 mole % lactic acid units and mixturesthereof having a number average molecular weight of 3,000-200,000 g/mol.

Due to the chiral (helical) nature of lactic acid, several distinctforms of polylactide exist: poly-L-lactide (PLLA) is the productresulting from polymerization of L,L-lactide (also known as L-lactide).PLLA has crystallinity around 37%, a glass transition temperaturebetween 50-80° C. and a melting temperature between 173-178° C. Thepolymerization of a racemic mixture L- and D-lactides leads to thesynthesis of poly-DL-lactide (PDLLA), which is not crystalline butamorphous. The physical blend of PDLA and PLLA can be used to widen thepolymer's application window.

Copolymers of lactic acid are typically prepared by catalyzedcopolymerization of lactide with one or more cyclic esters and/ordimeric cyclic esters. Typical co-monomers include glycolide(1,4-dioxane-2,5-dione), the dimeric cyclic ester of glycolic acid;β-propiolactone, the cyclic ester of 3-hydroxypropanic acid;α,α-dimethyl-β-propiolactone, the cyclic ester of2,2-dimethyl-3-hydroxypropanic acid; β-butyrolactone, the cyclic esterof 3-hydroxybutyric acid; δ-valerolactone, the cyclic ester of5-hydroxypentanoic acid; ε-caprolactone, the cyclic ester of6-hydroxyhexanoic acid, and the lactones of its methyl substitutedderivatives, such as 2-methyl-6-hydroxyhexanoic acid,3-methyl-6-hydroxyhexanoic, 4-methyl-6-hydroxyhexanoic acid,3,3,5-trimethyl-6-hydroxyhexanoic acid, etc., the cyclic ester of12-hydroxydodecanoic acid; and 2-p-dioxanone, the cyclic ester of2-(2-hydroxyethyl)-glycolic acid.

Further, according to the present invention, material, sourced frompotatoes, sugar cane or corn, biopolymer, such as PLA, naturallyoccurring zein, or poly-3-hydroxybutyrate based films and laminates areselected to maximize the renewable and recyclable materials content. Insome instances, the mattress can further include latex, such ascertified organic latex or Forest Stewardship Council certified (FSC)latex.

In another non-limiting embodiment of the present invention, themattress cover or outermost layer and/or outer layer of the mattressdoes not include food grade LDPE or food grade LLDPE. In thisembodiment, another polymer film such as PLA that has been FDAclassified as GRAS can be used in the mattress cover or outermost layerand or outer layer to provide a mattress with less or lower toxicitythan mattresses constructed of conventional components.

The outer layer 12 of a mattress 10, according to one embodiment of thepresent invention is shown in FIG. 1. Outer layer 12 can be composed ofa polyethylene or PLA film that can be heat fused to organic cotton,cotton, wool, polyester, polypropylene or other fabric substrates withinthe mattress so as to provide improved tensile strength and tearresistance to the outer layer of the mattress. In an alternativeembodiment, the outer layer 12 can be removed or be a separate piece tobe added or removed from the rest of the mattress 10.

The next lower layer 14 of the mattress 10, encompassed by the outerlayer, can include an industry approved fabric flame barrier which actsas a flame retardant instead of toxic halogenated flame retardants thatare commonly used.

The inner cushioning layer 16 of the mattress 10, encompassed by theouter layer and the next lower layer of the mattress can be composed ofan organically grown cotton batting or cushioning layer. In one aspect,the inner cushioning layer can be treated with ozone gas to clean,oxidize, and remove other possible contaminant volatiles. Alternately,the inner cushioning layer may be composed of a food grade LDPE or LLDPEor a PLA foam. In the foam form, the polymers of the present inventionfunction as packaging, vibration dampening and insulation, or as amaterial for cushioning.

The innermost component 18 of the mattress 10 embedded within the innercushioning layer is an innerspring which is constructed from metal orother polymeric support materials that are inherently less toxic thanother polymers which provide the same benefits including mattressstrength, cushioning, the required weight support and the desiredmattress shape. Of course, the layers could be constructed in anysuitable order to achieve a less toxic mattress. In addition, more orless layers could be used to form a less toxic mattress, including theuse of only three total layers.

FIG. 2A is an illustration of a mattress 200 in another exampleembodiment of the present invention. The mattress 200 includes a quiltlayer 202 as an outermost layer. The quilt layer 202 may be disposedabout the upholstery layers 204. The quilt layer 202 may be waterproof.The quilt layer 202 may be made with food-grade and/or non-toxicmaterial. The quilt layer 202 may be removably attached to theupholstery layers 204. For example, the quilt layer 202 and theupholstery layers 204 can be separated and washed independently.

The mattress 200 includes upholstery layers 204, at least partially,disposed below the quilt layer 202. The upholstery layers 204 may be anext lower layer. The upholstery layers 204 may be disposed about thebase core layer 206. The upholstery layers 204 may include one or morelayers made with a food-grade and/or non-toxic material. Each of thelayers of the upholstery layers 204 may be waterproof. The upholsterylayers 204 may be removably attached to the base core layer 206. Forexample, the upholstery layers 204 and the base core 206 can beseparated and washed independently.

The mattress 200 includes a base core layer 206, at least partially,disposed below the upholstery layers 204. The base core layer 206 may bean inner cushioning layer. The base core layer 206 may be disposed aboutthe foundation layer 208. The base core layer 206 may further include anenclosing intermediate layer 205. The intermediate layer 205 may bewaterproof. The intermediate layer 205 may be made with food-gradeand/or non-toxic material. The intermediate layer 205 may include afabric flame barrier which acts as a flame retardant.

The base core layer 206 may include supporting springs that areconstructed from metal or other polymeric support materials that areinherently less toxic than other polymers conventionally used inmattresses, and that provide the same benefits including mattressstrength, cushioning, the required weight support and the desiredmattress shape as may otherwise be provided by other polymersconventionally used in mattresses. The base core layer 206 could beconstructed in any suitable manner to achieve a less toxic mattress. Thebase core layer 2061 could also be constructed of other materials suchas latex or a foam.

The mattress 200 includes a foundation layer 208 disposed below the basecore layer 206. The foundation layer 208 is configured to provideadditional weight support. The foundation layer 208 can be waterproof.The foundation layer 208 can be made with food-grade and/or non-toxicmaterial. It is noted that arrangement of various layers in FIG. 2A isexemplary and is not limiting the disclosure in anyway.

FIG. 2B is an illustration of a mattress 210 in one embodiment of thepresent invention, in which the mattress includes a spring unit layer.The mattress 210 may include some or all of the various layers discussedin relation to FIG. 1 or FIG. 2A. It is noted that the arrangement ofvarious layers in FIG. 2B is exemplary and is not limiting thedisclosure in anyway.

FIG. 2C is an illustration of a mattress 220 in one embodiment of thepresent invention, in which the mattress includes an encased coil unit.The mattress 220 may include some or all of the various layers discussedin relation to FIG. 1 or FIG. 2A. It is noted that the arrangement ofvarious layers in FIG. 2C is exemplary and is not limiting thedisclosure in anyway.

FIG. 2D is an illustration of a mattress 250 in one embodiment of thepresent invention. Mattress 250 is one example in which the springlayers (e.g., spring unit or encased coil unit) illustrated in eithermattress 210 or 220 are replaced with a foam layer(s) (e.g., 256 and/or258, etc.). The mattress 250 may include a modal or velour fabric layer252 as a top layer. The mattress 250 may include a polyester waddinglayer 254 disposed below the modal or velour fabric layer 252. Themattress 250 may include a memory foam layer 256 disposed below thepolyester wadding layer 254. The mattress 250 may include a reflex foamlayer 258 disposed below the memory foam layer 256. The mattress 250 mayalso include a non-slip fabric layer 259 disposed below the reflex foamlayer 258. It is noted that arrangement of various layers in FIG. 2D isexemplary and is not limiting the disclosure in anyway.

In FIGS. 2A-2D, an outermost layer can be added to any of the examplemattress constructions. The outermost layer can be constructed of foodgrade and/or non-toxic material, such as food grade polyethylene. Also,any layer of the example mattress constructions could be constructed offood-grade and/or non-toxic material, such as food grade polyethylene.Additionally, any suitable number of the layers could be used incombination with a food-grade and/or non-toxic material, such as foodgrade polyethylene. And, any order of the layers can be used. For everylayer, food-grade and/or non-toxic material can be added, for example bymelting, onto the top or bottom of the layer.

FIG. 3A is a bassinet pad 300 according to one embodiment of thedisclosure. Non-limiting examples of the bassinet pad 300 can be a padfor a bassinet, a bassinette, a crib, or a cradle especially for babiesor young kids. As shown in FIG. 3A, the bassinet pad 300 includes a basefoam layer 315, a fabric layer 310, and a barrier layer 305. The barrierlayer 305 is waterproof. The bassinet pad 300 can be made in varioussizes, including for example, in sizes corresponding to standard childor adult mattress sizes for use as mattress pad for kids or adults.

In some embodiments, the bassinet pad 300 can have a thickness from ator about 1.75 to at or about 2.25 inches. In some embodiments, thebassinet pad 300 can have a thickness from at or about 1.5 to at orabout 2.5 inches. In some embodiments, the bassinet pad 300 can have athickness from at or about 1 to at or about 3 inches. In someembodiments, the bassinet pad 300 can have a thickness from at or about0.5 to at or about 4 inches. In some embodiments, the bassinet pad 300can have a thickness from at or about 1 to at or about 4 inches. In someembodiments, the bassinet pad 300 can have a thickness from at or about1.5 to at or about 3 inches.

In some embodiments, the barrier layer 305 can have a thickness from ator about 0.05 to at or about 2 inches. In some embodiments, the barrierlayer 305 can have a thickness from at or about 0.25 to at or about 2inches. In some embodiments, the barrier layer 305 can have a thicknessfrom at or about 0.5 to at or about 1.5 inches. In some embodiments, thebarrier layer 305 can have a thickness from at or about 0.75 to at orabout 1 inches.

In one embodiment, the barrier layer 305 is disposed about the fabriclayer 310. In one embodiment, fabric layer 310 is disposed about thebase foam layer 315. In one embodiment, the barrier layer 305 is heatfused about the fabric layer 310.

The barrier layer 305 can comprise food-grade and/or non-toxic material.For example, the barrier layer 305 can comprise one or more materialsselected from the following: Low Density Polyethylene (LDPE), Linear LowDensity Polyethylene (LLDPE), ultra-high-molecular-weight polyethylene(UHMWPE), ultra-low-molecular-weight polyethylene (ULMWPE or PE-WAX),high-molecular-weight polyethylene (HMWPE), high-density polyethylene(HDPE), high-density cross-linked polyethylene (HDXLPE), cross-linkedpolyethylene (PEX or XLPE), medium-density polyethylene (MDPE),very-low-density polyethylene (VLDPE), chlorinated polyethylene (CPE),Polylactic acid (PLA), polylactide, poly-L-lactide (PLLA),poly-DL-lactide (PDLLA), or combinations thereof. Non-toxic material mayalso include, without limitation, those categorized within ResinIdentification Codes 1 (polyethylene terephthelate), 2 (high-densitypolyethylene), 4 (low-density poly-ethylene), 5 (polypropylene), 6(polystyrene), or 7 (other plastics, such as polycarbonate, PLA, andacrylic). In preferred aspects, when these polymers are included in anylayer of the mattress they can also be food grade by FDA guidelines,such as those polymers provided in 21 C.F.R. 174-190. The abovementioned non-toxic materials may also be waterproofing materials.

In one embodiment, the LDPE or LLDPE has a density of 0.85 to 1.00 g/cc;a maximum extractable fraction (expressed as percent by weight of thepolymer) in n-hexane at specified temperatures is 5.5% at 50° C.; and amaximum extractable fraction (expressed as percent by weight of thepolymer) in xylenes at specified temperatures is 11.3% at 25° C.

In one embodiment, the non-toxic layer 305 can be attached to a topsurface of the fabric layer 310. In another embodiment, the non-toxiclayer 305 can be attached to a bottom surface of the fabric layer 310,e.g., in-between the fabric layer 310 and base foam layer 315.

In one embodiment, the non-toxic layer 305 can be heat fused or meltedonto the fabric layer 310. In another embodiment, the non-toxic layer305 can be heat fused or melted onto the backside of the fabric layer310, so that the fabric becomes the top layer and the non-toxic becomesthe lower layer.

The fabric layer 310 can be constructed of materials including cotton,organic cotton, polyester, polypropylene etc. or combinations thereof.In some embodiments, the fabric layer 310 can have a thickness from ator about 0.05 to at or about 4 inches. In some embodiments, the fabriclayer 310 can have a thickness from at or about 0.25 to at or about 3inches. In some embodiments, the fabric layer 310 can have a thicknessfrom at or about 0.5 to at or about 1.5 inches. In some embodiments, thefabric layer 310 can have a thickness from at or about 0.75 to at orabout 1 inches.

The base foam layer 315 may include a memory foam layer 315 disposedbelow the polyester wadding layer. The mattress 315 may include a reflexfoam layer disposed below the memory foam layer. The mattress 300 mayalso include a non-slip fabric layer disposed below the reflex foamlayer.

FIG. 3B is an embodiment of a mattress pad 370 disposed on top of amattress 365 according to one embodiment of the disclosure. The mattresspad 370 can be constructed in any size or shape suitable for thepurposes.

In one embodiment, the mattress pad 370 can be a pad detachably incontact with the mattress 365. The mattress pad 370 can be separatedfrom the mattress 365 and be cleaned or washed separately.

The mattress pad 370 includes at least two layers, a barrier layer 355and a fabric layer 360. The non-toxic layer comprises a hydrophobicmaterial and is waterproof.

The barrier layer 355 can comprise a material selected from thefollowings: Low Density Polyethylene (LDPE), Linear Low DensityPolyethylene (LLDPE), ultra-high-molecular-weight polyethylene (UHMWPE),ultra-low-molecular-weight polyethylene (ULMWPE or PE-WAX),high-molecular-weight polyethylene (HMWPE), high-density polyethylene(HDPE), high-density cross-linked polyethylene (HDXLPE), cross-linkedpolyethylene (PEX or XLPE), medium-density polyethylene (MDPE),very-low-density polyethylene (VLDPE), chlorinated polyethylene (CPE),Polylactic acid (PLA), polylactide, poly-L-lactide (PLLA),poly-DL-lactide (PDLLA), or combinations thereof. Non-toxic material mayalso include, without limitation, those categorized within ResinIdentification Codes 1 (polyethylene terephthelate), 2 (high-densitypolyethylene), 4 (low-density polyethylene), 5 (polypropylene), 6(polystyrene), or 7 (other plastics, such as polycarbonate, PLA, andacrylic). In preferred aspects, when these polymers are included in anylayer of the mattress they can also be food grade by FDA guidelines,such as those polymers provided in 21 C.F.R. 174-190. The abovementioned non-toxic materials may also be waterproofing materials.

In some embodiments, the barrier layer 355 can have a thickness from ator about 0.05 to at or about 3 inches. In some embodiments, the barrierlayer 355 can have a thickness from at or about 0.25 to at or about 2.5inches. In some embodiments, the barrier layer 355 can have a thicknessfrom at or about 0.5 to at or about 2 inches. In some embodiments, thebarrier layer 355 can have a thickness from at or about 0.75 to at orabout 1.5 inches.

In one embodiment, the barrier layer 355 can be attached to a topsurface of the fabric layer 360. In another embodiment, the barrierlayer 355 can be attached to a bottom surface of the fabric layer 360.

In one embodiment, the barrier layer 355 can be heat fused or meltedonto the fabric layer 360. In another embodiment, the barrier layer 355can be heat fused or melted onto the backside of the fabric layer 360,so that the fabric becomes the first layer and the polyethylene is thesecond layer.

The fabric layer 360 can be constructed of materials including cotton,organic cotton, polyester, polypropylene etc. or combinations thereof.In some embodiments, the fabric layer 360 can have a thickness from ator about 0.05 to at or about 2 inches. In some embodiments, the fabriclayer 360 can have a thickness from at or about 0.25 to at or about 2inches. In some embodiments, the fabric layer 360 can have a thicknessfrom at or about 0.5 to at or about 1.5 inches. In some embodiments, thefabric layer 360 can have a thickness from at or about 0.75 to at orabout 1 inches.

In one embodiment, the food-grade polyethylene can be the barrier layers305, 355. In one embodiment, the food-grade polyethylene can be heatfused or melted onto a fabric 310, 360, so that the first layer is thepolyethylene and the second layer is the fabric. In another embodiment,the food-grade polyethylene of the barrier layer 305, 355 can be heatfused or melted onto the backside of the fabric 310, 360, so that thefabric becomes the first layer and the polyethylene is the second layer.

Although the invention has been shown and described with respect to acertain preferred embodiment or embodiments, certain equivalentalterations and modifications will occur to others skilled in the artupon the reading and understanding of this specification and the annexeddrawings. In particular regard to the various functions performed by theabove described components, the terms (including a reference to a“means”) used to describe such components are intended to correspond,unless otherwise indicated, to any component which performs thespecified function of the described component (i.e., that isfunctionally equivalent), even though not structurally equivalent to thedisclosed structure which performs the function in the hereinillustrated exemplary embodiments of the invention. In addition, while aparticular feature of the invention may have been disclosed with respectto only one of several embodiments, such feature may be combined withone or more features of the other embodiments as may be desired andadvantageous for any given or particular application.

1. A mattress comprising: a core selected from the group of mattresscore types consisting of: polymeric cores and innerspring cores; abarrier layer enclosing the core, the barrier layer comprising afood-grade polypropylene compliant with U.S. Food & Drug Administration(FDA) standards in effect as of 7 Mar.
 2008. 2. The mattress of claim 1,where the food-grade plastic of the barrier layer is derived from anatural feedstock.
 3. The mattress of claim 1, where the core isconfigured to maintain the shape of the mattress.
 4. The mattress ofclaim 1, further comprising: a fabric flame barrier disposed between thecover and the core.
 5. The mattress of claim 1, further comprising: afabric layer overlying at least a portion of the barrier layer andaffixed to the barrier layer.
 6. The mattress of claim 5, where thefabric layer is quilted.
 7. The mattress of claim 5, where thefood-grade plastic of the barrier layer is melted onto an interiorsurface of the fabric layer.
 8. The mattress of claim 1, where thefood-grade plastic of the cover layer is heat fused to a substrate. 9.The mattress of claim 1, further comprising: a cushioning layer disposedbetween the core and the cover.
 10. The mattress of claim 9, where thecushioning layer comprises organically grown cotton.
 11. The mattress ofclaim 9, where the cushioning layer comprises a polymer foam.
 12. Themattress of claim 1, where the mattress is sized to fit a type offurniture selected from the group of furniture types consisting of:basinets, cribs, cradles, and beds.
 13. A pad or cover for a mattress,the pad or cover comprising: a barrier layer comprising a food-gradeplastic compliant with U.S. Food & Drug Administration (FDA) standardsin effect as of 7 Mar. 2008; where the barrier layer is configured to beremovably coupled to a mattress such that the barrier layer overlies atleast an upper support surface of the mattress.
 14. The mattress ofclaim 13, where the food-grade plastic of the barrier layer comprisesFood Grade Low Density Polyethylene.
 15. The mattress of claim 14,wherein the Food Grade Low Density Polyethylene of the barrier layer hasa density of 0.85 to 1.00 grams per cubic centimeter; a maximumextractable fraction (expressed as percent by weight of the polymer) inN-Hexane at specified temperatures is 5.5% at 50 Degrees Centigrade (DegC.); and a maximum extractable fraction (expressed as percent by weightof the polymer) in Xylene at specified temperatures is 11.3% at 25 DegC.
 16. The pad or cover of claim 13, where the food-grade plastic of thebarrier layer is derived from a natural feedstock.
 17. The pad or coverof claim 13, further comprising: a fabric flame barrier affixed to thebarrier layer on an interior side of the barrier layer such that whenthe barrier layer is coupled to a mattress the fabric flame barrierlayer is disposed between the mattress and the barrier layer.
 18. Thepad or cover of claim 13, further comprising: a fabric layer overlyingat least a portion of the barrier layer and affixed to the barrierlayer.
 19. The pad or cover of claim 18, where the fabric layer isquilted.
 20. The pad or cover of claim 18, where the food-grade plasticof the barrier layer is melted onto an interior surface of the fabriclayer.
 21. The pad or cover of claim 13, where the food-grade plastic ofthe cover layer is heat fused to a substrate.
 22. The pad or cover ofclaim 13, further comprising: a cushioning layer affixed directly orindirectly to the barrier layer on an interior side of the barrier layersuch that wen the barrier layer is coupled to a mattress the cushioninglayer is disposed between the mattress and the barrier layer.
 23. Thepad or cover of claim 22, where the cushioning layer comprisesorganically grown cotton.
 24. The pad or cover of claim 22, where thecushioning layer comprises a polymer foam.
 25. The pad or cover of claim13, where the mattress is sized to fit a type of furniture selected fromthe group of furniture types consisting of: basinets, cribs, cradles,and beds.